Packaging substrate and method of fabricating the same

ABSTRACT

A packaging substrate includes a first dielectric layer; a plurality of first conductive pads embedded in and exposed from a first surface of the first dielectric layer; a first circuit layer embedded in and exposed from a second surface of the first dielectric layer; a plurality of first metal bumps disposed in the first dielectric layer, each of the first metal bumps having a first end embedded in the first circuit layer and a second end opposing the first end and disposed on one of the first conductive pads, a conductive seedlayer being disposed between the first circuit layer and the first dielectric layer and between the first circuit layer and the first metal bump; a built-up structure disposed on the first circuit layer and the first dielectric layer; and a plurality of second conductive pads disposed on the built-up structure. The packaging substrate has an over-warpage problem improved.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims under 35 U.S.C. §119(a) the benefit of Taiwanese Application No. 100124360, filed Jul. 8, 2011, the entire contents of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to packaging substrates and methods of fabricating the same, and, more particularly, to a coreless packaging substrate and a method of fabricating the same.

2. Description of Related Art

With the rapid development of electronic industry, electronic products gradually move toward a trend of multi-functional and high performance. Currently, structure of semiconductor package has been developed into various types. For example, wire-bonding type or flip-chip type, is to set semiconductor chip on a packaging substrate. Besides, the semiconductor chip is connected to packaging substrate by bonding wires or solder bumps.

In order to meet the demand of high integration and miniaturization for connection and carrying of more active, passive components and wires, packaging substrate gradually evolves from double-layer board to multi-layer board. So that circuit area of packaging substrate can be broaden within limited space by interlayer connection, and can satisfy the operation requirement of integrated circuit with high circuit density. Moreover, thickness of packaging substrate can be lowered and the purpose of low-profiled and compact-sized structure and improved electric function can be achieved.

In prior art, packaging substrate is composed of core board with internal circuit and symmetric, built-up circuit structure. Owing to the thickness increment of overall structure using core board, it is difficult to satisfy the needs of improving function while shrinking substrate volume.

Thus, a coreless packaging substrate has been developed. Catch the trend of high-frequency and miniaturization by shortening circuit length and thickness of overall structure. As shown in FIG. 1, a coreless packaging substrate 1 is fabricated by the following steps of: forming a first dielectric layer 120 a on a carrier board (not shown) and forming a first circuit layer 11 on the first dielectric layer 120 a; forming a built-up structure 12 on the first dielectric layer 120 a and the first circuit layer 11, the built-up structure 12 having second, third and fourth dielectric layers 120 b, 120 c and 120 d, on which second circuit layers 121 that are electrically connected to one another by conductive vias 122 are formed; removing the carrier board to expose the first dielectric layer 120 a; forming a solder mask 14 a on the first dielectric layer 120 a, and forming another solder mask 14 b on the fourth dielectric layer 120 d and the second circuit layer 121; forming openings 140 a on the solder mask 14 a and the first dielectric layer 120 a to expose a portion of the first circuit layer 11, and forming another openings 140 b on the solder mask 14 b to expose a portion of the second circuit layer 121; and forming metal bumps 13 a and 13 b in the openings 140 a and 140 b, respectively, for bottom solder balls 15 a and top solder balls 15 b to be combined with, respectively, wherein a chip (not shown) may be disposed on the top solder balls 15 b, and a circuit board (not shown) may be disposed on the bottom solder balls 15 a. In the prior art, the packaging substrate 1 is fabricated in a bottom-up manner. In other words, the bottom side (i.e., a surface that is in contact with the carrier board) of packaging substrate 1 is fabricated first, then the intermediate components, such as the first to fourth dielectric layers 120 a to 120 d, are fabricated sequentially, and the metal bump 13 b and the solder mask 14 b are fabricated in the final step. In short, the packaging substrate 1 is fabricated from one side where the bottom solder balls 15 a are implanted to the other side where the chip may be disposed.

Wherein, one curing process needs to be performed whenever one of the dielectric layers 120 a to 120 d is formed, in order to cure the newly formed and half cured dielectric layers 120 a to 120 d. Besides, the greater the number of the curing process performed is, the more complete the gathering and shrinking of molecules in one of the dielectric layers 120 a to 120 d become. The curing processes affect all the dielectric layers. In the packaging substrate 1, the curing process is performed four, three, two and one time on the first to fourth dielectric layers 120 a to 120 d, respectively.

As above-mentioned, because of the different number of the curing process performed on the first to fourth dielectric layers 120 a to 120 d, the first to fourth dielectric layers 120 a to 120 d have different residual stress to gather and shrink. Since the curing process is performed on the first dielectric layer 120 a four times and is performed on the fourth dielectric layer 120 d one time only, the first dielectric layer 120 a has less residual stress than the fourth dielectric layer 120 d. Because each dielectric layer exerts centralizing, residual stress on the packaging substrate 1, in the prior art the packaging substrate 1 presents a phenomenon of warpage that the fourth dielectric layer side 120 d is sunken and the first dielectric layer side 120 a is bulged. To be more detailed, the packaging substrate 1 in which the chip-disposing side is an upper side is in the shape of “smile,” which is a characteristic of this kind of process, and the warpage phenomenon causes trouble to packaging substrate manufacture and to following packaging process, and then affects yield.

Notice that solder masks 14 a and 14 b are disposed on the first dielectric layer 120 a and fourth dielectric layer 120 d, respectively, and because the opening 140 a of the solder masks on the lower side 14 a is greater than the opening 140 b of the solder mask on the upper side 14 b, the actual covered area by the solder mask on the lower side 14 a is smaller than that by the solder mask on the upper side 14 b. That is, the upper solder mask 14 b has more material than the lower solder mask 14 a. The solder masks 14 a and 14 b also have residual stress to gather and shrink, so that the pull force from the upper solder mask 14 b exerted on the packaging substrate is greater than that from the lower solder mask 14 a, which causes warpage of packaging substrate 1 more serious (as indicated by a dotted line in FIG. 1).

In addition, the solder mask in the prior art and the external circuit layer it covers are non-coplanar, which also affects the yield and density of the package.

Therefore, how to overcome the over-warpage problem of the prior art is becoming the topic in urgent need to be solved.

SUMMARY OF THE INVENTION

In view of above-mentioned over-warpage problem of the prior art, the present invention provides a packaging substrate, including: a first dielectric layer having a first surface and an opposite second surface; a plurality of first conductive pads embedded in and exposed from the first surface of the first dielectric layer for a semiconductor chip to be disposed on the first conductive pads; a first circuit layer embedded in and exposed from the second surface of the first dielectric layer; a plurality of first metal bumps disposed in the first dielectric layer, each of the first metal bumps having a first end and an opposite end, wherein the first end is embedded in the first circuit layer, the second end is disposed on one of the first conductive pads, and a conductive seedlayer is disposed between the first circuit layer and the first dielectric layer and between the first circuit layer and the first metal bump; a built-up structure disposed on the first circuit layer and the first dielectric layer; and a plurality of second conductive pads disposed on the built-up structure for an external electronic device to be disposed on the second conductive pads.

The present invention further discloses a method of fabricating a packaging substrate, including: providing a carrier board having two opposite surfaces, on which a plurality of first conductive pads formed for semiconductor chips to be disposed on the first conductive pads; forming first metal bumps on the first conductive pads, each of the first metal bumps having a first end and an opposite second end, wherein the second end is disposed on one of the first conductive pads; covering the surfaces of the carrier board, the first conductive pads and the first metal bumps with a first dielectric layer that has a plurality of first intaglios for exposing top and side surfaces of the first ends of the first metal bumps, respectively; forming a conductive seedlayer on the first dielectric layer and the first ends of the first metal bumps; forming a metal layer on the conductive seedlayer; removing a portion of the metal layer and the conductive seedlayer that is over a top surface of the first dielectric layer, and forming a first circuit layer in the first intaglios; forming a built-up structure on the first circuit layer and the first dielectric layer, an outermost layer of the built-up structure having second conductive pads for an external electronic device to be disposed on the second conductive pads; and removing the carrier board.

From the foregoing contents, the packaging substrate of the disclosed embodiments are fabricated from chip-disposing side to side that connects an external electronic device. This made the overall packaging substrate with final chip-disposing side up in the shape of “anti-smile.” But removed area of first dielectric layer (top dielectric layer) is smaller than that of bottom dielectric layer, generating a stress that makes packaging substrate in the shape of “smile.” Finally, the stress of “smile” and “anti-smile” offset each other, causing overall packaging substrate to be more flat.

In addition, packaging substrate made by the disclosed embodiments with conductive pads and dielectric layer flush on the surface is beneficial to package process of high density for the increment of density of conductive pads.

Besides, the disclosed embodiments replace solder mask of green painting in prior art with dielectric layer, so that material of each layer of packaging substrate is uniform and pure, which is beneficial to the stability and smoothness of overall packaging substrate. The yield is also promoted.

Furthermore, method of laser ablation is not necessary for process of metal bumps in the disclosed embodiments. Although laser is capable of raising overall speed through adjustment, laser forms one via at a time. Thus, the disclosed embodiments can reduce process time effectively by forming a plurality of metal bumps simultaneously. The cost is also lowered. And reliability of combination in disclosed embodiments is raised by embedding metal bumps into circuit layer.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and desired objects of the subject invention, reference is made to the following detailed description taken in conjunction with the accompanying drawing figures wherein like reference character denote corresponding parts throughout the several views and wherein:

FIG. 1 (PRIOR ART) is a cross-sectional side view of a coreless packaging substrate of the prior art;

FIGS. 2A-2O are cross-sectional side views of a packaging substrate and a method of fabricating the packaging substrate according to a first embodiment of the present invention;

FIGS. 3A-3E are cross-sectional side views of a packaging substrate and a method of fabricating the packaging substrate according to a second embodiment of the present invention; and

FIGS. 3A′-3D′ are cross-sectional side views of a packaging substrate and a method of fabricating the packaging substrate according to a third embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The following is explanation of the disclosed embodiments by examples, and those who are familiar with this technical field can easily understand the advantages and efficacy by the explanation.

Notice that the illustrated structure, ratio and size of appended figures in the explanation are only used for the disclosed embodiments in the explanation for understanding and reading of those who are familiar with this technical field. It is not applicable for limiting implementing condition of the disclosed embodiments, so the illustration doesn't have actual meaning in the technical field. Any modification of structure, change of ratio and adjustment of size should fall in the disclosed embodiments when the efficacy and purpose of the disclosed embodiments are not affected. Meanwhile, the terms that are quoted in the explanation like “upper,” “a” and so on only intent for convenience of description rather than limiting feasible scope of the disclosed embodiments. Change or adjustment of relative relationship under no actual alteration of content of technique should be seen as feasible scope of the disclosed embodiments.

Please refer to FIGS. 2A to 2O, which illustrate a method of fabricating a packaging substrate of a first embodiment according to the present invention.

As shown in FIG. 2A, a carrier board 20 is provided with two opposing surfaces 20 a, each of which is provided with a plurality of first conductive pads 22, for semiconductor chips 28 to be disposed thereon (referring to FIG. 2O). The carrier board 20 includes a supporting layer 201 and medium layers 202 formed on two opposing surfaces of the supporting layer 201. The first conductive pads 22 are disposed on the medium layers 202.

As shown in FIG. 2B, first metal bumps 23 are disposed on the first conductive pads 22. Each of the first metal bumps has a first end 23 a and a second end 23 b opposing the first end 23 a, and the second end 23 b is connected to one of the first conductive pads 22.

In an embodiment of the present invention, the first metal bumps 23 are made of copper, nickel, tin, gold, silver or copper-tin alloy, and are made in, but not limited to, an additive process, a semi-additive process, a subtractive process, an electroplating process, an electroless plating deposition process, a chemical deposition process or a printing process.

As shown in FIG. 2C, first dielectric layers 24 covers surfaces 20 a of the carrier board 20, the first conductive pads 22, and the first metal bumps 23.

As shown in FIG. 2D, a plurality of first intaglios 240 are formed in the first dielectric layers 24 to expose top and side surfaces of the first ends 23 a of the first metal bumps 23.

As shown in FIG. 2E, conductive seedlayers 25 are formed on the first dielectric layers 24 and the first ends 23 a of the metal bumps 23.

As shown in FIG. 2F, metal layers 26 are formed on the conductive seedlayers 25.

As shown in FIG. 2G, a portion of the metal layers 26 and the conductive seedlayers 25 higher than a top surface of the first dielectric layers 24 are removed, thereby forming first circuit layers 261 in the first intaglios 240.

In addition to the electroplating technique, the first circuit layer 261 can also be formed by forming a mask layer (not shown) on the structure shown in FIG. 2C, and patterning the mask layers by laser to form the first intaglios 240 shown in FIG. 2D; then comprehensively forming an active layer (not shown). In an embodiment of the present invention, the active layer can be formed by a dipping technique. In detail, the active layer can be soaked in a chemical solution consisting essentially of a plurality of metal granules, where the granules can be adhered to the mask layers, a surface of the first intaglios 240, an exposed top surface and a side surface of the first ends 23 a, thereby forming the active layer. The metal granules can be palladium, platinum, gold or silver, for example. The palladium granules could be made from colloid of tin-palladium chloride or chelator of palladium sulfate. The mask layers and the active layer formed thereon are then removed. Finally, a first circuit layer 261 is formed on the active layer in the first intaglios 240, as shown in FIG. 2G, by an electroless plating technique. All of the embedded circuit in the disclosed embodiments can apply the above-mentioned method to form, so the following would not explain anymore.

As shown in FIGS. 2H to 2L, the processes from FIGS. 2B to 2G are performed iteratively, so as to form second metal bumps 271 and second dielectric layers 272. The method of forming the second metal bumps 271 can refer to the method of forming the first metal bumps 23 mentioned above. A plurality of second intaglios 272 a that expose top surfaces and side surfaces of third ends 271 a of the second metal bumps 271 are formed in the second dielectric layers 272. Second circuit layers 273 are formed in second intaglios 272 a. Second metal bumps 271, second dielectric layers 272 and second circuit layers 273 may be formed subsequently, if necessary, in order to form a built-up structure 27 on the first circuit layers 261 and the first dielectric layers 24. The built-up structure 27 includes at least a second dielectric layer 272, a second circuit layer 273 embedded in and exposed from a surface of second dielectric layer 272, and a plurality of second metal bumps 271 formed in the second dielectric layer 272 and electrically connected to the first circuit layer 261 and the second circuit layer 273 or electrically connected to the second circuit layers 273. Each of the second metal bumps 271 has a third end 271 a and a fourth end 271 b opposing the third end 271 a, with the third end 271 a of the second metal bumps 271 embedded in the second circuit layers 273, and the second conductive pads 273 a disposed on the outermost one of the second circuit layers 273. In this way, overall laid-out packaging substrate 2 in upper-and-lower pairs is constructed. Besides, the outermost layers of the built-up structure 27 can also have a plurality of conductive pads 273 a for an external electronic device to be connected thereto. This is the overall laid-out packaging substrate 2 in upper-and-lower pairs.

Notice that, though the conductive seedlayers of built-up structure 27 are not illustrated, it should be known that second circuit layer 273 of this example of embodiment can be formed by the electroplating and follow-up polishing procedure of the conductive seedlayers (Similar to the steps from FIGS. 2E to 2G).

As shown in FIG. 2M, the carrier board 20 is removed to separate the overall packaging substrate 2 in upper-and-lower pairs to become two overall substrates 2′.

As shown in FIG. 2N, a singulation process is performed, to obtain a plurality of packaging substrates 2″.

As shown in FIG. 2O, a semiconductor chip 28 is disposed on the first conductive pads 22, and solder balls 29 are disposed on the second conductive pads 273 a. In an embodiment of the present invention, the packaging substrates 2″ are divided first and the semiconductor chip 28 is then disposed on the first conductive pads 22. The semiconductor chip 2″ may also be disposed on the first conductive pads 22 first and the singulation process is performed on the packaging substrate.

Please refer to FIGS. 3A to 3E, which are cross-sectional views of a packaging substrate and a method of fabricating the same of a second embodiment according to the present invention.

The second embodiment differs from the first embodiment in the process and structure of built-up structure.

Specifically, the built-up structure 31 in the second embodiment is fabricated by forming a second dielectric layers 311, and then vias 311 a and second intaglios 311 b are formed in the second dielectric layers 311. Conductive vias 312 and second circuit layers 313 are formed in the vias 311 a and the second intaglios 311 b, respectively. That is, the built-up structure 31 in the second embodiment includes at least a second dielectric layer 311, second circuit layers 313 embedded in and exposed from the second dielectric layer 311, and a plurality of vias 312 formed in the second dielectric layer 311 and electrically connected to the first circuit layer 261 and the second circuit layer 313 or electrically connected to the second circuit layers 313. Besides, the outermost one of the second circuit layers 313 has second conductive pads 313 a.

Please refer to FIGS. 3A′ to 3D′, which are cross-sectional views of a packaging substrate and a method of fabricating the same of a third embodiment according to the present invention. The third embodiment differs from the second embodiment in that a built-up structure 31′ in the third embodiment is not embedded in a second dielectric layer.

In detail, the built-up structure 31′ in the third embodiment is fabricated by forming a second dielectric layer 311′, forming vias 311 a′ in the second dielectric layers 311′, and forming conductive vias 312′ and second circuit layer 313′ on the vias 311 a′ and the second dielectric layer 311′, respectively. That is, the built-up structure 31′ includes at least a second dielectric layer 311′, a second circuit layer 313′ formed on the second dielectric layer 311′, and a plurality of conductive vias 312′ formed in the second dielectric layer 311′ and electrically connected to the first circuit layer 261 and the second circuit layer 313′ or electrically connected to the second circuit layers 313′. Besides, the outermost one of the second circuit layers 313′ has second conductive pads 313 a′.

The disclosed embodiments provide a packaging substrate, including: a first dielectric layer 24 with opposing first surface 24 a and second surface 24 b, a plurality of first conductive pads 22 embedded in and exposed from the first surface 24 a of the first dielectric layer 24 for a semiconductor chip 28 to be connected to the first conductive pads 22, a first circuit layer 261 embedded in and exposed from the second surface 24 b of the first dielectric layer 24, and a plurality of first metal bumps 23 disposed in the first dielectric layer 24, wherein each of the metal bumps has opposing first end 23 a and second end 23 b, the second end 23 b connected to the first conductive pad 22, the first end 23 a embedded in the first circuit layer 261. The packaging substrate further comprises a conductive seedlayer 25 disposed among the first circuit layer 261, the first dielectric layer 24 and the first metal bumps 23, built-up structures 27, 31 or 31′ disposed on the first circuit layers 261 and the first dielectric layers 24, and a plurality of second conductive pads 273 a, 313 a or 313 a′ disposed on the outermost layers of the built-up structure 27, 31 or 31′ for an external electronic device to be connected thereto.

In the above-mentioned packaging substrate, the built-up structure 27 includes at least a second dielectric layer 272, a second circuit layer 273 embedded in and exposed from the surface of second dielectric layer 272, and a plurality of second metal bumps 271 disposed in second dielectric layer 272 and electrically connected to first circuit layer 261 and the second circuit layer 273 or electrically connected to second circuit layers 273, each of the second metal bumps having a third end 271 a embedded in the second circuit layer 273 and a fourth end 271 b opposing the third end 271 a. The outermost one of the second circuit layers has second conductive pads 273 a.

As above-mentioned packaging substrate, the built-up structure 31 includes at least a second dielectric layer 311, a second circuit layer 313 embedded in and exposed from the surface of second dielectric layer 311, a plurality of vias 312 disposed in the second dielectric layer 313 and electrically connected to the first circuit layer 261 and the second circuit layer 313 or electrically connected to the second circuit layers 313. The outermost one of the second circuit layers 313 has second conductive pads 313 a.

In the packaging substrate mentioned above, the built-up structure 31′ includes at least a second dielectric layer 311′, a second circuit layer 313′ disposed on the second dielectric layer 311, a plurality of vias 312′ disposed in the second dielectric layer 311′ and electrically connected to the first circuit layer 261 and second circuit layer 313′ or electrically connected to the second circuit layers 313′. The outermost one of the second circuit layers 313′ has second conductive pads 313 a′.

In an embodiment of the present invention, the external electronic device can be a circuit board or other package structures.

To sum up, a packaging substrate in the disclosed embodiments is fabricated from chip-disposing side to the side connected to an external electronic device, which causes the overall packaging substrate with final chip-disposing side upon in the shape of “anti-smile.” Because the removed area of the first dielectric layer (top dielectric layer) is smaller than the bottom dielectric layer, stress generated that makes packaging substrate in the shape of “smile.” Finally the stress of “smile” and “anti-smile” offset, causing overall packaging substrate more flat.

Besides, packaging substrate made in the disclosed embodiments with conductive pads and dielectric layer flush on the surface can raise the density of conductive pads, which is beneficial to package process of high density.

And the disclosed embodiments replace solder mask of green painting in prior art with dielectric layer, causing material of each layer uniform and pure, which is beneficial for stability and smoothness of overall packaging substrate. Yield is also raised.

Furthermore, it is not necessary for process of metal bumps in the disclosed embodiments to use traditional method of laser ablation, though laser can raise overall speed through adjustment, laser can only form a via at a time. Thus, the disclosed embodiments form a plurality of metal bumps simultaneously can effectively reduce time of process and cost down. By embedding metal bumps in circuit layers, contact area between the circuit layer and metal bumps increases, so the combination of both is better, and then overall reliability is raised.

Above-mentioned examples of embodiments illustratively explain theory and efficacy of the disclosed embodiments rather than limiting the disclosed embodiments. Anyone who is familiar with this technical field can make alterations if the spirit and scope of the disclosed embodiments are not violated. Thus the scope of rights protection should be accordance with the following list. 

What is claimed is:
 1. A packaging substrate, comprising: a first dielectric layer having a first surface and an opposite second surface; a plurality of first conductive pads partially embedded in and exposed from the first surface of the first dielectric layer for a semiconductor chip to be disposed on the first conductive pads; a first circuit layer partially embedded in and exposed from the second surface of the first dielectric layer; a plurality of first metal bumps disposed in the first dielectric layer, each of the first metal bumps having a first end and an opposite second end, wherein the second end of the first metal bump is disposed on the first conductive pad, the first end of the first metal bump is embedded in the first circuit layer, and a conductive seedlayer is disposed between the first circuit layer and the first dielectric layer and between the first circuit layer and the first metal bump; a built-up structure disposed on the first circuit layer and on the second surface of the first dielectric; and a plurality of second conductive pads disposed on the built-up structure for an external electronic device to be disposed thereon.
 2. The packaging substrate of claim 1, wherein the built-up structure comprises at least a second dielectric layer, a second circuit layer embedded in and exposed from the second dielectric layer, and a plurality of second metal bumps disposed in the second dielectric layer and electrically connected to the first circuit layer and the second circuit layer or electrically connected to the second circuit layers, wherein the second metal bump having a third end and an opposite fourth end, the third end of the second metal bump is embedded in the second circuit layer, and the second conductive pads are disposed on an outermost one of the second circuit layers.
 3. The packaging substrate of claim 1, wherein the built-up structure comprises at least a second dielectric layer, a second circuit layer embedded in and exposed from the second dielectric layer, and a plurality of conductive vias disposed in the second dielectric layer and electrically connected to the first circuit layer and the second circuit layer or electrically connected to the second circuit layers, wherein the second conductive pads are disposed on an outermost one of the second circuit layers.
 4. The packaging substrate of claim 1, wherein the built-up structure comprises at least a second dielectric layer, a second circuit layer disposed on the second dielectric layer, and a plurality of conductive vias disposed in the second dielectric layer and electrically connected to the first circuit layer and the second circuit layer or electrically connected to the second circuit layers, wherein the second conductive pads are disposed on an outermost one of the second circuit layers. 